20 Quick Heat Treat News Chatter Items to Keep You Current

Heat Treat Today offers News Chatter, a feature highlighting representative moves, transactions, and kudos from around the industry.

Personnel & Company Chatter

  • Bharat Forge America Inc. will build an aluminum forging plant to manufacture automobile components in Sanford, North Carolina.
  • Ipsen USA recently announced the completion of an initiative to expand aftermarket services across the United States and Canada. Five regional sales engineers (RSEs) were hired over the last six months to assist customers with replacement parts, retrofits, upgrades, service, and technical support for any brand of atmosphere or vacuum heat-treating system.
  • An industrial heating technology company, Kanthal, recently launched an additive manufacturing service that will produce heating elements and components, as well as developing a new iron-chromium-aluminum alloy called Kanthal AM100.
  • GKN Aerospace has been selected as a key supplier on the new Gulfstream G700 business jet. The company is using its expertise in the design and manufacture of business jet empennages and thermoplastic components on the advanced aircraft. The rudder and elevators that are part of the empennage, as well as the floorboards, feature the latest thermoplastic technology. GKN Aerospace also produces the bonded fuselage panels for the new fuselage.
  • A ribbon-cutting ceremony recently marked the opening the new corporate headquarters and manufacturing facility of Process Cooling Systems, Inc. in Massachusetts.
  • Gasbarre Thermal Processing Systems recently partnered with Humberto Bastidas from Thermal Technic Furnace Solutions.  Gasbarre will be working with Humberto and his team to launch a Spanish version of Gasbarre.com in the coming weeks and will assist with other marketing efforts in that region.
  • A manufacturer of products from carbon recently provided large, custom Sigrabond Performance CFC fixtures to a North American aerospace company. By replacing the current alloy fixture with the new CFC fixtures from SGL Carbon, the customer increased part/fixture weight ratio from 62/38 to 87/13.
  • Two electrically heated multi-zone curing ovens were recently shipped to the composites industry by Wisconsin Oven for the purpose of curing carbon fiber threads.
  • A Model FB1046 floor-standing box furnace has been shipped by L&L Special Furnace Co, Inc., to a worldwide leader of high tech aerospace and associated components located in the Southeastern United States. The furnace will be used for processing aerospace parts and various thermal applications.
  • Danieli Olivotto Ferrè recently started up a tube roller hearth annealing furnace at Tenaris Tamsa, in Veracruz, part of one of the world’s largest manufacturers of steel pipe for the energy and automotive industries. The furnace is designed to treat steel tubes coming from cold or hot processing with a maximum throughput of 5 tons/h. The flexible furnace is able to perform different heat-treatment cycles, including normalizing, annealing, tempering and stress relieving. In addition, Danieli has been selected to supply the new electric arc furnace (EAF) melt shop and plate-/steckel-mill, as well as an electrical and automation package provided by Danieli Automation, for Nucor Corporation and its new greenfield plate steel mill complex in Brandenburg, Kentucky.
  • Dana Incorporated announced the expansion of a joint engineering agreement with Fendt, a worldwide brand of AGCO.  Over the past three years, the companies have co-developed advanced Spicer® 980 independent suspended axles for the new Fendt 900 Vario series of large tractors.
  • Allegheny Technologies Incorporated announced it signed another 1-year agreement to extend and expand carbon steel hot-rolling conversion services for NLMK USA at its world-class hot rolling and processing facility, or HRPF, located in Brackenridge, Pennsylvania.
  • A global leading stainless steel manufacturer with headquarters in Spain, Acerinox, S.A., has reached an agreement for the acquisition from Lindsay Goldberg Vogel GmbH and Falcon Metals BV. of VDM Metals Holding GmbH, with headquarters in Germany and leading producer of specialty alloys.
  • A vacuum furnace for processing additive manufactured parts has been shipped to a large science and technology laboratory by Solar Manufacturing. The lab requires the furnace to further research and development work.
  • Through its subsidiary, Tenova Goodfellow Inc., Canada, Tenova installed and commissioned a peak shaver at VINA Kyoei Steel, Vietnam, providing continuous improvement for melt shop operations.
  • A Ph.D. student at the University of Strathclyde in Glasgow, Scotland, Lewis Print is the inaugural winner of an international student award in industrial heating, the Kanthal® Student Award, presented by industrial heating technology company Kanthal. The award has been made for his work on the development of new technology for the production of silicon carbide (SiC) heating elements used in high-temperature industrial processes operating in the range 2012°F-2912°F (1100°C-1600°C).
  • At the October fall meeting in Vancouver, Canada, the Metal Treating Institute (MTI) recognized Mary Springer from Thermtech in Waukesha, Wisconsin, with the Heritage Award. The Heritage Award is MTI’s most prestigious award.
  • The Center for Materials Processing Data (CMPD) recently announced three organizations have committed to the Center’s inaugural Industry Member class: Pratt & Whitney (a founding industry member), MTS Systems Corporation, and Weber Metals. This commitment, operating to solidify its formation, has allowed CMPD to greenlight a pilot project focused on the material flow behavior as a function of temperature, strain rate, composition, and prior microstructure processing.
  • Pelican Wire was named the winner of the 25th annual Southwest Florida Blue Chip Community Business Award at this year’s luncheon and awards ceremony. Chosen by an independent panel of judges, the criteria are centered around overcoming adversity to achieve success.
  • ASB Industries, Barberton, Ohio, announced that Charles Kay, ASB vice president, was recognized as an ASM Fellow at the annual ASM Awards Banquet in October. The award citation states, “For global technical leadership in innovative thermal spray technologies, mentoring thermal spray practitioners, and sustained dedicated volunteer service to the thermal spray community.”

Heat Treat Today is pleased to join in the announcements of growth and achievement throughout the industry by highlighting them here on our News Chatter page. Please send any information you feel may be of interest to manufacturers with in-house heat treat departments especially in the aerospace, automotive, medical, and energy sectors to editor@heattreattoday.com

20 Quick Heat Treat News Chatter Items to Keep You Current Read More »

IHEA Takes to the High Seas for the 2020 Annual Meeting

Royal Caribbean’s Brilliance of the Seas

The Industrial Heating Equipment Association recently announced its 91st Annual Meeting will be held on the high seas from March 12 – 16, 2020, on Royal Caribbean’s Brilliance of the Seas, departing from Tampa, FL. IHEA has had several very successful, high-quality annual meetings on cruise ships and is excited to offer this budget-friendly meeting to IHEA members once again.

This four-day event will feature two sea days and a day in Cozumel. As always, the annual meeting promises to deliver outstanding programming, committee work, and plenty of time for social interaction during the receptions and meal functions.

Chief Master Sergeant (Retired) Bob Vazquez

The program will include presentations from some of IHEA’s past favorites: Chief Master Sergeant (Retired) Bob Vazquez, Chris Kuehl, and Omar Nashashibi. Chief is a course director at the United States Air Force Academy’s Center for Character Development, as well as an adjunct professor at the University of Colorado at Colorado Springs. He will be talking to attendees about the Power of SUPERvision. IHEA is happy to welcome him back four years later for his unique perspective on leadership.

IHEA’s economist Chris Kuehl

 

Attendees will also hear from IHEA’s economist Chris Kuehl, who entertains as well as informs the crowd with his spirited delivery of the economic update. With all eyes and ears on Washington, Omar Nashashibi, a Washington D.C. lobbyist will present an insider’s perspective as the 2020 presidential election unfolds. As a bonus for all attendees, speakers will be available throughout the cruise to continue discussions and answer questions in a more relaxed setting.

Omar Nashashibi

IHEA committees will convene on board the Brilliance of the Seas to continue work on issues of importance to the membership and the industry at large. The complete program and event details will be available on the website, www.ihea.org, in early December.

The four-night cruise will depart from Tampa, FL on Thursday, March 12 and will return to Tampa on Monday morning, where guests will disembark to return home. As there are a variety of stateroom classes available onboard Brilliance of the Seas, IHEA has secured cabins in several different categories to provide cost flexibility to members. The cabin price is for one or two guests in the cabin. There is no discount for a single passenger in a cabin.

The annual reeting registration fee includes all committee and general session meetings, and evening receptions. There will be no registration fee for spouses/guests to attend the meeting.

IHEA Takes to the High Seas for the 2020 Annual Meeting Read More »

Smart Materials, Magnesium Alloys Manufacturer Breaks Ground on Expanded Foundry

A manufacturer of smart materials for the oil and gas industry and advanced magnesium alloys for lightweighting recently broke ground on its expanded magnesium foundry for manufacturing dissolvable metals.

Andrew Sherman, CEO of Terves

Terves Inc launched the 12,000 sq. ft. expansion to its Magnesium Foundry, an H3-classified magnesium metal processing facility expansion which enables the company to further expand its metal processing, heat treatment, machining, and storage capabilities.  The expansion plans include additional permanent mold and materials handling and storage space, and the addition of sand casting, squeeze casting, and diecasting capabilities for custom magnesium and magnesium alloys and composites, in addition to further expansion of build-to-print component CNC machining services. These additions enable the company to support aerospace and defense magnesium applications in addition to Terves’ leading position in the dissolvable oilfield tool market.

 

“Dissolvable Metals are the New Composites as far as oilfield tools are concerned,” said Andrew Sherman, CEO of Terves. “Oilfield tools made from composite materials were adopted in the industry about two decades ago and today occupy a sizable market share. We are seeing a major adoption and growth trajectory for oilfield tools made from dissolvable magnesium materials. At the end of 2017, roughly 2% of all frac plugs deployed in the field were being made using dissolvable metals and the market is expected to grow to 5% of all frac plugs deployed in the field by the end of 2018 – a 250% growth in one year, with adoption and use increasing through 2025. We are seeing tremendous innovation as the industry gains extensive field experience with these new Engineered Response multifunctional materials, including several new staging and completion tools engineered using dissolvable materials. Given the massive value-add of dissolvable tools, primarily eliminating post-completion drill-outs coupled with the ability to do longer laterals, we expect that dissolvable tools would replace over 30% of drillable tools used in well completion over the next 3-5 years. Terves is investing in a further doubling of production capacity for cast and wrought magnesium products, and the expansion frees up space in existing facilities for initial production of new Engineered Response products, including revolutionary expandable structural materials and gas-generating reactive materials.”

 

Smart Materials, Magnesium Alloys Manufacturer Breaks Ground on Expanded Foundry Read More »

Heat Treat Radio #22: New SECO/WARWICK CEO Speaks Out

Welcome to another episode of Heat Treat Radio, a periodic podcast where Heat Treat Radio host, Doug Glenn, discusses cutting-edge topics with industry-leading personalities. Below, you can either listen to the podcast by clicking on the audio play button, or you can read an edited version of the transcript. To see a complete list of other Heat Treat Radio episodes, click here.


Audio: New SECO/WARWICK CEO Speaks Out

In this conversation, Sĺawomir Woźniak recounts his history with SECO/WARWICK. Heat Treat Today publisher and Heat Treat Radio host, Doug Glenn puts the questions to new SECO/WARWICK global CEO, Sĺawomir Woźniak regarding the direction of SECO/WARWICK in North America. Hear what this long-time SECO employee, now CEO, has to say about global manufacturing, technology developments, and the impact of augmented reality (AR) on the heat treat world. The interview took place at the world’s largest heat treating event in Germany, Thermprocess, in late June of this year.

Click the play button below to listen.


Transcript: New SECO/WARWICK CEO Speaks Out

The following transcript has been edited for your reading enjoyment.

In June of 2019, the parent company of SECO/WARWICK Corporation and SECO/VACUUM Technologies, both located in western Pennsylvania, appointed a new CEO at their Poland location. In late June, less than a month after taking the reins, Sĺawomir Woźniak sat down with Heat Treat Today at Thermprocess in Düsseldorf, Germany, to talk about his vision for the company and specifically what plans he has for North America.

It was very hot in Düsseldorf at the end of June this year, so Mr. Woźniak and I were glad to be inside at the world's largest heat treating event, Thermprocess 2019. The Thermprocess event is held every four years in Düsseldorf, and SECO/WARWICK was there in a major way with one of the largest, if not the largest, displays, and a full-on contingent of people. The global headquarters for SECO/WARWICK is in the sleepy-sized city of Świebodzin, Poland, about halfway between Berlin, Germany, and Warsaw, Poland. Originally, an American company, SECO/WARWICK is now one of the major global players in the heat treat market with manufacturing or sales locations in nearly all major industrial countries, including India, China, Europe, and North America.

Taking the reins of the company is a longtime SECO employee, Sĺawomir Woźniak, or "Slawek" for short. After attempting to pronounce Mr. Woźniak's name, I got the thumbs up and then he gave us the history of his time with SECO.

Slawek: I have been working for SECO/WARWICK for more than 20 years. I started from floor level, being an electrician. When I was in high school, I started working for SECO/WARWICK as an electrician making control panels, wiring equipment, and so on. When I graduated from university, then I started in the service field. At that time, SECO/WARWICK was a quite small organization; this was 1999. I had an opportunity to service vacuum furnaces, atmosphere furnaces, and aluminum processing equipment.

The largest indexing CAB furnace in North America sold to Cold Shot Chillers in Houston TX to conduct in-house furnace brazing of the company’s heat exchangers.

Also, that particular year, SECO/WARWICK transferred know-how for CAB—control aluminum brazing equipment—from SECO/WARWICK Corporation to Poland to send up European market for SECO/WARWICK. It was also a time when I started to be more involved in CAB product line. I was working as a service engineer for the first project SECO/WAWRICK built in Poland for CAB. Gradually, we also had more projects, and we restructured our organization and had a team structure. We created, at that time, what we called the "aluminum team." When we say aluminum, it was aluminum process and control atmosphere brazing equipment for brazing of aluminum heat exchangers.

I held the position of project manager, then again I was moved to service and became a service manager over the team for that particular product line. The more projects we had, the more people we hired for our team. When the team was quite large, we decided to restructure our team there. We separated the aluminum process with control atmosphere brazing equipment as a separate team, and I became the deputy team leader and Piotr Skarbinski was at that time the team leader of aluminum brazing equipment.

In 2010, when SECO/WARWICK decided to open a new joint venture in China, then I moved to China and became a vice general manager over our Chinese operation there. From that time, I started to learn how to really manage a business, complete a P&L, and so on. A year after that in 2011, my former boss left our corporation and I then also became managing director of SECO/WARWICK Retech in China. I managed the company, and in the meantime, I was fortunate to have an opportunity to be involved in our India operation. I had been in charge of the India operation as a residence managing director for a couple of years.  Then we created a holding company in Poland, so I also took responsibility as the operational excellence director. I was in charge to transfer some good practices between the companies in our group.

In January 2017, SECO/WARWICK announced that SECO/WARWICK Allied Pvt. Ltd. would be relocating to a new operating facility in Mahape, Navi Mumbai, India.

That led me to a position later on as executive director of Asian operations. Since 2010, I have been more on the operational side, especially for Asia and subsidiaries. We had two companies in Asia at that time; there was an Indian operation and a Chinese operation, and I overlooked both of those companies.

Doug: Slawek went on to describe some of the restructuring and operational improvements that were executed in Asia which brought us up to June 5, 2019, which was a day that Mr. Wozniak's candidacy for the position of CEO of the global company was accepted by SECO/WARWICK'S advisory board.

I next asked Slawek to discuss plans for the North American market.

Slawek: We have a very strong footprint on various locations geographically, and we actually would like to be on every continent but not necessarily with manufacturing. Nowadays, the economic situation for many companies, not only our company, requires them to restructure operations and to focus on the fabrication of the equipment of the location where we can be cost-effective. The location where we still see big opportunities to run the business between the others obviously is America, we would definitely like to have a strong presence, but not necessarily fabrication. We would like to focus more on product development, which is actually what we are still doing, and we will continue concentrating on the vacuum metallurgical equipment which is Retech, services, and aftermarket activities.

Retech has experienced significant growth in the number of sales of vacuum induction nelting (VIM) systems; in 2018, it was most frequently sold product from the whole range of Retech’s vacuum metallurgical equipment.

Today we have three locations, three companies in the US. We have a Retech located in California, a subsidy of SECO/WARWICK Group. We have two companies in Pennsylvania, obviously—SECO/WARWICK Corporation where everything started, the whole story of SECO/WARWICK. Our focus is very strongly on development, on time to run this business, but absolutely I would like to express with 100% confidence that we are not going out of the business in the US. We like to be there. We would even like to build some equipment but not necessarily in-house. This is actually what we do now: we still build equipment in the US in SECO/WARWICK Corporation, some aluminum process equipment, aluminum melting equipment, but we do build our equipment through our subcontractors.

We have a good database of subcontractors. Within the last few years, we were developing the subcontractors because there was a long-term strategy in the back of our heads that we would restructure our operation in the US in SECO/WARWICK Corporation. And that is what happened last year.  e decided to shut down in-house manufacturing in SECO/WARWICK Corporation, but we are still in business. We are hiring people. We would like to develop our products. We concentrate mainly on aluminum process and thermal processing equipment. We have good technology and we have good database and customers and we would like to keep a relationship.

We felt that our activities in aftermarket were not that strong, so we are now increasing our activities. This week we made an announcement on the global level that we promoted Robert Szadkowski as vice president for aftermarket, and I assigned Robert to be responsible for the development of the American market for aftermarket. We would like to reinforce our operation there as regards to the services, so we just recently hired a new sale/service person and have sent him to Poland for a couple of weeks for training. We are really looking forward to rebuilding our market position regarding the supplier of goods, rebuilds, services, and spare parts. Obviously, we are keeping in mind that we would like to still continue with the fabrication of the equipment and delivering projects to current customers.

Over the last decade, Poland has become an important base to produce high-quality and state-of-the-art products in Europe.

The second company we have in our group is SVT, SECO/VACUUM Technologies, which is also located in Meadville, Pennsylvania. This company is mainly focused on serving North American customers by providing vacuum furnaces solutions and nitriding furnaces solutions. The furnaces are purely built in Poland and exported to the US or North American market and then delivered by SECO/VACUUM Technologies, and all axillary equipment can be delivered from US market. All of the services, including installing and commissioning, can be purely done by our colleagues from the SECO/VACUUM Technologies.

The companies in Pennsylvania, we will continue with them definitely. We changed our business model, but it is not a downgrade of our operation. We increase our strength in Poland because we want to build more equipment in Poland, and then we send this equipment to the US to compete with other companies which actually round the business in similar model.

Doug:  So where is SECO going globally? I asked Slawek to comment.

Slawek:  We would like to see our company grow as a leading supplier of heat treat equipment, and we would like to provide a complete solution and added value to our customers. We would like to be recognized on the market as a reputed supplier with very good and strong service. And finally, we would like to continue with our presence on every continent as we already decided to be in India, Asia, and North America. We would also like to double up our business partners, like sales agents in various locations.

Speaking about India, although we closed in-house manufacturing and we do not have full operation in India, we still have a footprint there. We have a good performing small sales and service-oriented company, and we can deliver some equipment from other locations to that plant, even from China where we have manufacturing. We would like to reinforce ourselves in sales and service in various locations, whereas manufacturing, we would like to maintain where it is cost-effective and we can say that we have competence. We can keep our engineering and we can develop our products.

Doug:  Slawek comments further on the company's commitment to research and development of new products.

Slawek:  SECO/WARWICK grew up from the engineering background, and we are an innovative company. We don't want to just be a follower. We would like to innovate, we would like to create something new on the market. This is why we have to spend a good part of our income on R&D and we are doing it.

Doug:  I asked Slawek to comment more on the company's commitment to R&D. Here's what he had to say:

SECO/VACUUM Technologies (SVT)worked with a prominent aerospace equipment manufacturer to bring their low pressure carburizing and hardening work in-house. SVT supplied its signature CaseMaster Evolution® (CMe) dual-chamber vacuum oil quench furnace to improve their lead times and quality objectives.

Slawek:  As of today, I can say that we have two R&D centers in our group. One is located in US, mainly for vacuum metallurgical products and the other is located in Europe for other business lines. We are still running our R&D projects. Even at this show, we are presenting two new products: Super IQ and UCM 4D Quench, which is a very nice product. Tomorrow we will have a speech by Dr. Korecki who will present this new idea to the market. I strongly believe that these two products can be very successful, not only in the European market but especially in the US market where the economy is improving and we see a lot of good activities from the US market.

Doug:  At Thermprocess, SECO unveiled, among other things, SECO/Lab, which I asked Slawek to comment on.

Slawek:  SECO/Lab is a philosophy that we would like to provide to our customers as well and share our experience with our customers. We developed equipment in Poland in our laboratory. As I mentioned, we have three laboratory testing furnaces in California, and I would like to see even more equipment to be installed in the US. Since we don't have manufacturing in the US for vacuum metallurgical equipment, we would like to still convince our customers that our idea know-how is there. We are creating equipment that is designed in the US and made in Europe. We would like to develop even further our R&D presence in US especially for this business segment.

We have a very nice laboratory in Poland, in Świebodzin, our main location in Europe. We can do the testing in our equipment and then also test the samples, like a microstructure. We also have a relationship and even some agreement with universities, so if we cannot do some tests or some research in our laboratory, then we can cooperate with some university and then we can continue our trials with help of universities.

SECO Lens

Doug:  I next asked Slawek to say something about what SECO/WARWICK was doing with respect to augmented reality, artificial intelligence, and generally, the Internet of Things.

Slawek:  That is a very good question because you can hear about augmented reality or the Internet of Things or Industry 4.0 almost everyday everywhere. This is an area we addressed a long time ago and we are working on some new products. We are about to launch a predictive maintenance product which will be the product which will support our customers and equipment especially, to predict some potential failure of the equipment which can lower the maintenance costs or break-down costs of the equipment. You probably have heard of SECO/Lens, so this is a combination of Microsoft Hololens with augmented reality or you can even operate our equipment using this technology, which can be also a potential future to cope with the shortage of goods, services, talents, or service engineers. Giving such a solution to the customer can be like an extension of a good, experienced service engineer so the operator can go around the furnace and use this SECO/Lens technology to operate the furnace and to maintain or even fix the problem on the furnace, like a maintenance tool. This is under development at the moment, and I believe this is the future.

Doug:  As a final question, we tried to get a glimpse of what excites and motivates this new CEO. I put the question to him: When you're lying in bed at night, and you're thinking about the future of SECO/WARWICK, what excites you?

Slawek:  I always love the challenge. When I had the opportunity to move to China in 2010, the green field, the new company, take my family—two kids (five years old at the time) and my wife and move to China and live there for a couple of years, that was my first challenge. The second challenge I had was when I took the opportunity to be a nonresident managing director of the Indian operation. I was living in China, flying to India every other week, and that was another challenge. After those two challenges, I would say that to take a challenge to be the CEO of SECO/WARWICK group, you have to just do it, yes?

Doug Glenn, Publisher, Heat Treat Today
Doug Glenn, Heat Treat Today publisher and Heat Treat Radio host.


To listen to more Heat Treat Radio episodes, click here.

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Nucor Contracts Quenching Unit, Caster for Kentucky Plate Mill Facility

A company that provides construction and mechanical engineering for the steel and nonferrous metals industry was recently selected for the supply of new equipment for a new plate mill facility, including a quenching unit, a single-strand caster, and other key elements of the production chain.

Nucor Corporation selected The SMS Group to design and produce the single-strand caster for ultra-wide and thick slabs for an annual capacity of 1.45 million tons (1.6 million short tons) at Nucor’s new plate mill facility in Brandenburg, Kentucky. The new casting machine is expected to be one of the largest casters worldwide.

Johnny Jacobs, vice president and general manager of Nucor Brandenburg

“SMS group and Nucor make a good team, and the caster will be essential to the success of our new plate mill facility,” said Johnny Jacobs, vice president and general manager of Nucor Brandenburg.

Incorporated in the project are several special technological features, including robotic applications on the casting platform and an HD mold with fiber optics and electromagnetic stirring, as well as a customized roller apron, a quenching unit, and a second cutting line.

 

Main photo caption: (L-R) Keith Watson, SMS Group vice president; Burkhard Dahmen, SMS Group GmbH president and CEO; John Ferriola, Nucor chairman and CEO; Leon Topalian, Nucor president and COO

Nucor Contracts Quenching Unit, Caster for Kentucky Plate Mill Facility Read More »

Heat Treat Tips: Where You Measure Matters

During the day-to-day operation of heat treat departments, many habits are formed and procedures followed that sometimes are done simply because that’s the way they’ve always been done. One of the great benefits of having a community of heat treaters is to challenge those habits and look at new ways of doing things. Heat Treat Today’s annual 101 Heat Treat Tips, tips and tricks that come from some of the industry’s foremost experts, were featured in the 2019 Heat Treat Show Edition, as a way to make the benefits of that community available to as many people as possible. This edition is available in a digital format here.

Today we offer the first Heat Treat Tip from the 2019 edition: Debbie Aliya of Aliya Analytical Inc. on “Where You Measure Matters”, categorized under Materials Testing. Debbie is also one of Heat Treat Today’s featured Heat Treat Consultants. Click here for more information on our Consultants’ page.


Heat Treat Tip #6

Where You Measure Matters

Eugene Gifford Grace (August 27, 1876 – July 7, 1960) was the president of Bethlehem Steel Corporation from 1916 to 1945. He also served as president of the American Iron and Steel Institute and sat on the board of trustees for Lehigh University, of which he was an alumnus. One of his famous quotes is as follows:

“Thousands of engineers can design bridges, calculate strains and stresses, and draw up specifications for machines, but the great engineer is the man who can tell whether the bridge or the machine should be built at all, where it should be built, and when.”

If you check out the additional accomplishments of Mr. Grace, you will see that he was a successful and smart person. Maybe all of us are not capable of reaching such breadth of vision as he articulated above, but as heat treaters, do we simply accept the specification given? Or do we stop to ask if the specification has been properly determined?

With modern computer added stress analysis (FEA), we have at our fingertips a way to move beyond both the “guess and test” and the “copy the historical spec” methods of determining the case depth. Within “guess and test,” of course there are scientific guesses and scientific wild guesses. If you are using a wild guess, chances are that the field is the test lab!

Figure 1. Metallurgical mount holding a cross-section of the steel gear.

Especially for carburized components, deeper case is more time in the furnace, and thus more expensive. I continue to wonder why, if even back in the 1950s, thousands of engineers were available who could calculate stresses and strains and thus set a quantitative foundation for a case depth, in 2019, so few people take advantage of modern technology to optimize the cost of their products.

If you are not ready to take this big step toward design optimization, maybe you would consider always using effective case depth, based on hardness and thus linked to tensile strength, instead of total case depth, which is not linked to any durability or strength criteria.

Figure 1 shows the metallographic cross-section that was used to measure the hardness. Each white pin point is a Knoop 500 gram hardness indentation. The cross-section of the gear was mounted in black epoxy resin. Figures 2 to 4 show the data collected to determine the effective case depths to the common Rockwell C 50 criteria.

Figure 2. Knoop 500 gram hardness data converted to Rockwell C at the tooth flank.

Figure 3. Same data but for Root position.

Figure 4. Same data as shown in Figure 3, near surface information easier to see.

The effective case depth is the depth where the hardness dips below HRC50. For Gear Tooth Flank A, that value was 0.85 mm. For another gear from the same lot, it was over 1.08 mm. But for the root areas, between the teeth—the high-stress area, the effective case depths were only 0.45 and 0.65 mm, respectively. Figure 3 shows the same data as Figure 2, but using a logarithmic scale, illustrating what’s going on near the surface layers more clearly.

In any case, there’s a big difference between the two test locations, and this shows the importance of making sure that all relevant features of the component are adequately characterized!


If you have a heat treat-related tip that would benefit your industry colleagues, you can submit your tip(s) to doug@heattreattoday.com or editor@heattreattoday.com. 

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Texas Aluminum Company Invests, Restarts Rolling Mill

 

Source: Light Metal Age

 

A Texas-based aluminum company recently launched operations of its previously idled aluminum rolling mill with a ribbon-cutting ceremony.

Texarkana Aluminum produces common alloy for the North American service center industry is a fully integrated aluminum rolling mill with casting, hot mill, cold mill, and finishing capabilities. Ta Chen International Inc, which owns Texarkana, invested $460 million to restart the previously idle rolling operation. Included in the plans are software and hardware upgrades for the rolling mill and a goal of 300 million lbs of aluminum coil production per year once the plant reaches full operation.

The event at the plan in Nash, Texas, was attended by company executives as well as local, regional and state economic and political organizations.

“This plant will be fully operational come May 2020,” said Calum Donnachie, chief operating officer of Texarkana Aluminum Inc.

Read more: “Texarkana Aluminum Opens Aluminum Rolling Plant”

Main photo credit / caption: Hunt Mercier of Texarkana Gazette / Arkansas Gov. Asa Hutchinson speaks to Harvey Wrubel at the Texarkana Aluminum ribbon-cutting ceremony in Nash, Texas. 

 

 

Texas Aluminum Company Invests, Restarts Rolling Mill Read More »

Alfa Romeo Racing Invests in High-Pressure Heat Treatment

A Swiss company that operates Alfa Romeo Racing recently partnered with a global leader in high-pressure heat treatment (HPHT) technology for processing high-performance materials.

Christoph Hansen, head of technical development at Sauber Engineering AG

Sauber Motorsport AG, a part of the Sauber Group of Companies, launched a long-term partnership with Title Sponsor Alfa Romeo in 2018 and have now chosen Quintus Technologies to supply their hot isostatic pressing (HIP) equipment.

"The partnership with Quintus is an important milestone on Sauber Engineering’s Additive Manufacturing journey" said Christoph Hansen, head of technical development at Sauber Engineering AG. "The implementation of the hot isostatic pressing process adds massive value in bringing performance to our car as well as for the demanding needs of our customers. By using Quintus’s HIP technology, the Sauber Group will be able to push the boundaries of what we do even further and bring the materials we produce to an outstanding level."

Jan Söderström, CEO of Quintus Technologies

With the QIH 21 M URQ®, Alfa Romeo Racing has access to Quintus’s proprietary URQ® technology, which allows heat treatment and cooling to be combined in a single process, known as high-pressure heat treatment. The QIH 21 M URQ® has an operating temperature of 2,552°F (1,400°C).

"We are excited to be partnering with one of the most iconic Formula One teams—Alfa Romeo Racing," said Jan Söderström, CEO of Quintus Technologies. “This collaboration brings together two organizations at the forefront of advanced development and product innovation in the AM field. Working with Alfa Romeo Racing also gives us at Quintus a unique opportunity to show a large audience how well the modern HIP technology optimizes material properties."

Main photo credit: Speedcafe

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IHEA’s Economic Summary Reports “Steady as She Goes”

New Auto/Light Truck Sales continue to rise

Despite predictions that trade wars, oil prices, and cautious business decisions would slow economic growth, the economic readings, reported monthly by the Industrial Heating Equipment Association’s Executive Economic Summary, “show some of that caution, but many had expected a drastic reduction in activity by this point, and that has not emerged.”

Trending upward were nine areas including those with a small bump from the sales of new automobiles and light trucks. This steady rise has been reflected throughout the year, from last December’s high at 1,749 million to this month’s 1,718 million.

Over the past several months there has been a marked improvement in metal price data. The PMI New Orders that had been on a sharp decline over the past months have leveled off and are similar to last month’s reading.

Metals Pricing shows distinct improvement over last several months

The biggest jump was reflected in the new home starts with multi-family and high-end sectors driving the market; additionally, there was a bump in commercial building. Steel consumption also saw a rise due to the demand of vehicle manufacturers.

According to IHEA’s economist, if there is an overall conclusion it’s that most of the dire predictions concerning the economy have not come to fruition, however, there remains considerable unease. “The variables have been hard to determine–much less predictable.”

Ann Goyer, Executive Director of IHEA
Anne Goyer, Executive Director of IHEA

The 12-page monthly report is comprised of an introductory summary page, and then one page each to analyze in detail eleven indices chosen specifically for their impact on the thermal processing market.

To receive a full copy of this report, contact Anne Goyer, Executive Director of IHEA

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The Class of 2019 40 Under 40: Meet Joshua Braun-Wagner & Colin Pashia

Heat Treat Today is privileged to oversee the 40 Under 40 recognition awards, highlighting a group of young, up-and-coming talent in the North American heat treat industry every year. This year’s Class of 2019 is no disappointment, a group of industry elite, significant contributors to the heat treat market.

Every couple of weeks we highlight two of the current class of recipients. This week we introduce Joshua Braun-Wagner of Advanced Heat Treat Corp. and Colin Pashia of ABB Motors & Mechanical, Inc.


Name: Joshua Braun-Wagner

Company: Advanced Heat Treat Corp

Position: Induction Supervisor

Josh is an integral part of Advanced Heat Treat Corp’s induction department development, scheduling work load, writing machine programs, developing process instructions for new parts, working with customers ranging from agriculture to construction to machine shops, and managing 3 shifts in his department. While initially hired into an entry-level position, his leadership skills were quickly realized, and he was promoted into a management position within only a couple months of employment. One particular area in which he thrives is being able to tweak the machine to produce a “good”  part per customer parameters, without warping or cracking. Always up for a challenge, Josh’s ability to produce finished customer parts is a key aspect of maintaining our customer base as well as expanding it. Josh was also instrumental in purchasing two new induction machines for our facility in 2019. From the design of the machine to the safety features of the machines, to the installation, and now production, Josh has been there in the thick of it all. We certainly could not have done it without his expertise on induction hardening.

Nominated by: Advanced Heat Treating Corp


Name: Colin Pashia

Company: ABB Motors & Mechanical, Inc.

Position: Project Engineer & Metallurgist

 Colin has a true passion for heat treatment and metallurgy. He was the former chief metallurgist for ABB/Baldor in the U.S. Southeast and took on the title of project manager at ABB Motors & Mechanical to gain practical experience on the shop floor. He brings experience in initial recipe development of induction heat treatment of bearing and gearing products; performing root cause failure analysis of bearings, gearings, and PT components; qualifying potential new raw material suppliers against internal and industry standards; evaluation of low pressure carburizing process for bearing product; maintaining a metallurgical lab for consumables for new lab equipment. He is currently engaged with new induction purchases and new batch I.Q. purchases. At 28, Colin is the future of our industry.

Nominated by: Baldor Electric


Read more about the feature at Heat Treat Today’s 40 Under 40 resource page and find out more about each of this year’s winners by clicking on their image. To nominate someone for the Class of 2020 40 Under 40, please click here.

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